Fastener injector system and method

ABSTRACT

A fastener injector ( 18 ) includes a plurality of tubes ( 86 ) operable to transfer a plurality of different sizes and types of fasteners ( 20 ) in a desired orientation. The injector also includes a receiver ( 88 ) operable to receive the fasteners ( 20 ) in the desired orientation from the tubes ( 86 ). The receiver ( 88 ) includes a plurality of receiver fingers ( 90 ) operable to receive the fasteners ( 20 ) from the tubes ( 86 ) and retain the fasteners ( 20 ) in the desired orientation. An injector blade ( 106 ) is operable to transfer the fasteners ( 20 ) in the desired orientation from the receiver ( 88 ) to a fastener installation device.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.09/178,024 filed Oct. 23, 1998, entitled “Fastener Injector System andMethod,” now U.S. Pat. No. 6,196,414. This application is also relatedto U.S. patent application Ser. No. 09/178,169, filed Oct. 23,1998entitled “Orientation Maintained Fastener Delivery System andMethod, and U.S. patent application Ser. No. 09/178,167, filed Oct. 23,1998, entitled “Fastener Escapement System and Method.”

TECHNICAL FIELD OF INVENTION

This invention relates generally to fastener delivery systems and, moreparticularly, to a fastener injector system and method.

BACKGROUND OF THE INVENTION

Fastener delivery systems are generally used to retrieve fasteners froma storage area and transport the fasteners to an automatic fastenerinstallation device. One example of a fastener delivery system includesa feeder bowl, a tube, and a fastener injection device. The feeder bowlgenerally contains a large number of loosely contained fasteners. Thefasteners exit the feeder bowl and enter the tube through a generallyfunnel-shaped device. A pneumatic power supply is generally used totransport the fasteners through the tube to the fastener injectiondevice. The fastener injection device manipulates the fastener into anorientation capable of being received by the automatic fastenerinstallation device and delivers the fastener to the automatic fastenerinstallation device.

In mass production, several feeder bowls are often used so that avariety of sizes or types of fasteners may be transported to thefastener installation device to meet specific fastener installationrequirements. For example, one feeder bowl containing one size offastener may be replaced with another feeder bowl containing a differentsize fastener so that the same tube and injector can be used toaccommodate a variety of fastener installation requirements.Accordingly, the tube and fastener injection device are generallydesigned to accommodate a variety of sizes or types of fasteners.

However, because the tube and fastener injection device are designed toaccommodate a variety of sizes or types of fasteners, the orientation ofthe fastener is uncontrolled until the fastener reaches the fastenerinjection device. For example, the tube is generally designed having adiameter large enough to accommodate the largest sized fastener out of avariety of sizes or types of fasteners. Thus, the fastener is allowed totumble loosely through the tube during transport from the feeder bowl tothe fastener injection device. Once the fastener reaches the fastenerinjection device, the fastener must be manipulated into an orientationacceptable for being received by the fastener installation device andfor installation.

However, manipulating each fastener after reaching the fastenerinjection device is time consuming and inefficient. For example, thefastener injection device may be unable to or incapable of manipulatingthe fastener into an acceptable installation orientation. As a result,the fastener must be purged from the fastener injection device andanother fastener sent from the feeder bowl to complete the fastenerinstallation sequence.

SUMMARY OF THE INVENTION

Accordingly, a need has arisen for an improved fastener injector systemthat provides increased fastener orientation control. The presentinvention provides an improved fastener injector system that addressesshortcomings of prior fastener injector systems and increases fastenerorientation control.

According to one embodiment of the invention, a fastener injectorincludes a receiver operable to receive a plurality of different sizesand types of fasteners in a desired orientation. The injector alsoincludes an injector blade operable to deliver the fasteners in thedesired orientation from the receiver to a fastener installation device.

According to another embodiment of the invention, a method fordelivering a plurality of different sizes and types of fasteners to afastener installation device includes delivering the fasteners in adesired orientation to a receiver using a plurality of tubes. The methodalso includes transferring the fasteners in the desired orientation fromthe receiver to the fastener installation device using an injectorblade.

The invention provides several technical advantages. For example, in oneembodiment of the invention, receiving and maintaining a fastener in adesired orientation by the injector provides greater efficiency thanprior fastener injectors by decreasing the amount of time required tomanipulate the fastener into an acceptable installation orientation. Inthe same embodiment, the fastener injector provides greater flexibilitythan prior fastener injectors by accommodating a variety of sizes andtypes of fasteners.

Other technical advantages will be readily apparent to one skilled inthe art from the following figures, descriptions, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and theadvantages thereof, reference is now made to the following descriptionstaken in connection with the accompanying drawings in which:

FIG. 1 is a schematic drawing illustrating an isometric view of afastener delivery system constructed in accordance with the teachings ofthe present invention;

FIG. 2 is a schematic drawing illustrating an enlarged isometric view ofan escapement shown in the fastener delivery system of FIG. 1;

FIG. 3 is a schematic drawing illustrating a plan view of the escapementshown in FIG. 2;

FIG. 4 is a schematic drawing illustrating an enlarged isometric view ofa distributor shown in the fastener delivery system of FIG. 1;

FIG. 5 is a schematic drawing illustrating an exploded assembly view ofthe distributor shown in FIG. 4;

FIG. 6 is a schematic drawing illustrating an enlarged isometric view ofan injector shown in the fastener delivery system of FIG. 1;

FIG. 7 is a schematic drawing illustrating an injector blade of theinjector shown in FIG. 6; and

FIG. 8 is a flow chart illustrating the steps performed in accordancewith the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention and its advantages are bestunderstood by referring to FIGS. 1-7 of the drawings, like numeralsbeing use for like and corresponding parts of the various drawings.

FIG. 1 is a schematic drawing illustrating an isometric view of afastener delivery system 10 constructed in accordance with the teachingsthe present invention. The embodiment of fastener delivery system 10illustrated in FIG. 1 includes a plurality of feeder bowls 12, aplurality of escapements 14, a transfer system 16, and an injector 18.Escapements 14 receive fasteners 20 from feeder bowls 12 and deliverfasteners 20 in a desired orientation to transfer system 16. Transfersystem 16 transports fasteners 20 in the desired orientation fromescapements 14 to injector 18. Injector 18 delivers fasteners 20 in thedesired orientation to an automatic fastener installation device 22 forinstalling fasteners 20 in a variety of structures. Maintaining thedesired orientation of fasteners 20 throughout fastener delivery system10 will be described in greater detail in conjunction with FIGS. 2-7.

Fastener delivery system 10 also includes a controller or processor 24.Processor 24 comprises a computer, workstation, mini-computer, mainframeor other computing device for controlling operation of fastener deliverysystem 10. For example, as will be described further in conjunction withFIG. 2, processor 24 activates feeder bowls 12 to initiate delivery offasteners 20 from feeder bowls 12 to escapements 14. In one embodiment,processor 24 includes a logic sequencer manufactured by Allen Bradleyunder part number PLC 5; however, other suitable equipment or devicesmay be used for processor 24. The logic sequences for controllingfastener delivery system 10 can be readily programmed by those havingordinary skill in the art.

As illustrated in FIG. 1, feeder bowls 12 of fastener delivery system 10provide a storage or holding area for fasteners 20. Each feeder bowl 12may include a different size or type of fastener 20 thereby providingincreased flexibility of fastener delivery system 10 by allowing avariety of installation requirements to be met using fastener deliverysystem 10. For example, each feeder bowl 12 may contain a differentlength of the same type of fastener 20. The different types or sizes offasteners 20 are entered or stored in processor 24 corresponding tofeeder bowls 12 containing the particular sizes or types of fasteners20. Depending on a particular installation requirement, fastener 20 maybe selected from an appropriate feeder bowl 12 to meet the particularinstallation requirement. An example of feeder bowl 12 includes a{fraction (5/32)} inch rivet bowl manufactured by Performance Feedersfor Northrop Grumman Corporation under part number P-296351; however,other suitable storage or containment devices may be used as a storageor holding area for fasteners 20. Each feeder bowl 12 has an escapement14 disposed adjacent an outlet (not explicitly shown) of feeder bowl 12for receiving fasteners 20 from feeder bowl 12. In the embodimentdescribed above, a vibrating motion of feeder bowl 12 causes fasteners20 to exit the outlet of feeder bowl 12 and enter escapement 14. Theoperation of escapement 14 will be described in greater detail inconjunction with FIGS. 2 and 3.

Transfer system 16 of fastener delivery system 10 includes tubes 26, adistributor 28, and tubes 30. In operation, escapements 14 receivefasteners 20 from feeder bowls 12 and deliver fasteners 20 in thedesired orientation to tubes 26 of transfer system 16. A power supply(not explicitly shown), such as a pneumatic or other suitable powersupply, propels fasteners 20 in the desired orientation through tubes26, distributor 28, and tubes 30 to injector 18. In one embodiment,tubes 26 and 30 are constructed using nylon tubing material; however,other suitable materials may be used to construct tubes 26 and 30. Aswill be described further in conjunction with FIGS. 4 and 5, distributor28 aligns one of tubes 26 with one of tubes 30 depending upon aparticular size or type of fastener 20 selected to meet a particularinstallation requirement.

FIG. 2 is a schematic drawing illustrating an enlarged isometric view ofescapement 14 shown in FIG. 1. In the embodiment illustrated in FIG. 2,escapement 14 includes side plates 32 and 34 and a spacer 36. Spacer 36is disposed between side plate 32 and side plate 34 creating a passage38 between side plate 32 and side plate 34. Feeder bowl 12 deliversfasteners 20 into passage 38 of escapement 14 so that heads 40 offasteners 20 are seated above side plates 32 and 34. Accordingly, shanks42 of fasteners 20 are disposed within passage 38. Thus, fasteners 20are positioned in a desired orientation within passage 38 of escapement14 upon receipt from feeder bowls 12.

Escapement 14 also includes a regulator 44 for controlling the deliveryof fasteners 20 from escapement 14 to transfer system 16. Regulator 44includes a power supply 46, a release blade 48, and a stop blade 50.Release blade 48 and stop blade 50 extend into passage 38 through anopening 52 in side plate 32. In operation, release blade 48 and stopblade 50 extend and retract to regulate the delivery of fasteners 20 totube 26 of transfer system 16. An example of regulator 44 includes aDura-scape manufactured by R & I Manufacturing under model number BC-2B;however, other suitable methods or devices may be used to control thedelivery of fasteners 20 to transfer system 16. The operation of releaseblade 48 and stop blade 50 of regulator 44 will be described in greaterdetail in conjunction with FIG. 3.

In the embodiment illustrated in FIG. 2, escapement 14 also includes ashield 54. Shield 54 is disposed above fasteners 20 and passage 38 toprevent foreign objects from entering passage 38 and to preventfasteners 20 from exiting passage 38. For example, as best illustratedin FIG. 1, escapements 14 are disposed adjacent feeder bowls 12 at anangle so that gravity assists in moving or transporting fasteners 20within passage 38 toward regulator 44. Accordingly, referring to FIG. 2,shield 54 prevents fasteners 20 from exiting or falling out of passage38. In the embodiment illustrated in FIG. 2, a removable knob 56 and ashield bracket 58 are used to position shield 54 above fasteners 20 andpassage 38. Knob 56 and shield bracket 59 provide for easy removal andreplacement of shield 54 to perform such functions as inspecting,cleaning, purging, or the like, passage 38.

Escapement 14 shown in FIG. 2 also includes a power supply mountingbracket 60, a fastener drop 62, and a tube bracket 64. Power supplymounting bracket 60 provides a location for attaching a power supply(not explicitly shown) for propelling fasteners 20 through transfersystem 16 to injector 18. The power supply, such as a pneumatic or othersuitable power supply, may be attached to power supply mounting bracket60 at opening 66. However, other methods of coupling the power supply totransfer system 16 may be used to transfer fasteners 20 from escapement14 to injector 18.

Fastener drop 62 of escapement 14 is disposed below power supplymounting bracket 60 for receiving fasteners 20 from passage 38 anddelivering fasteners 20 to transfer system 16 in the desiredorientation. As illustrated in FIG. 2, tube 26 of transfer system 16 isattached to tube bracket 64 so that fasteners 20 are transferred frompassage 38 to transfer system 16 through fastener drop 62. The operationof fastener drop 62 for delivering fasteners 20 to transfer system 16 inthe desired orientation will be described in greater detail inconjunction with FIG. 3.

As illustrated in FIG. 2, fastener delivery system 10 also includessensors 68 and 70 coupled to escapement 14. Sensor 68 initiates deliveryof fasteners 20 from feeder bowls 12 to escapements 14. For example,sensor 68 is disposed adjacent passage 38 a predetermined distance fromregulator 44 so that sensor 68 detects whether fasteners 20 are presentwithin passage 38. If sensor 68 detects that additional fasteners 20 arerequired within passage 38, sensor 68 transmits a signal to processor 24indicating the need for additional fasteners 20. In response, processor24 activates feeder bowls 12 for the delivery of fasteners 20 toescapement 14. Additionally, when sensor 68 detects that an adequatesupply of fasteners 20 are present within passage 38, sensor 68transmits a signal to processor 24 indicating the receipt of an adequatesupply of fasteners 20 within escapement 14. In response, processor 24deactivates feeder bowls 12 to cease the delivery of additionalfasteners 20 from feeder bowls 12 to escapement 14. One type of sensor68 that may be used with fastener delivery system 10 is manufactured byTurck Incorporated under part number BI2U-M12-AN4X-H1141; however, othersuitable sensors or indicating devices may be used. Therefore, fastenerdelivery system 10 provides for an automatic and efficient method ofdelivering fasteners 20 from feeder bowls 12 to escapements 14.

Additionally, sensor 68 may be used to notify a user of fastenerdelivery system 10 that feeder bowls 12 are empty, malfunctioning, orthe like. For example, if sensor 68 detects that additional fasteners 20are required within passage 38 of escapement 14, sensor 68 transmits asignal to processor 24 to activate feeder bowls 12 and initiate deliveryof fasteners 20. A predetermined time period may be entered or stored inprocessor 24 so that if processor 24 does not receive a signal fromsensor 68 indicating the receipt of an adequate supply of fasteners 20within the predetermined time period, the user is notified thatescapement 14 is not receiving fasteners 20. Thus, fastener deliverysystem 10 provides greater reliability than prior art fastener deliverysystems by notifying the user of fastener delivery system 10 thatfasteners 20 may not be available to perform additional installations.

Sensor 70 of fastener delivery system 10 activates the power supply forpropelling fasteners 20 through transfer system 16 to injector 18. Forexample, after regulator 44 releases a single fastener 20 from passage38, sensor 70 detects fastener 20 entering fastener drop 62. Once sensor70 detects fastener 20 entering fastener drop 62, sensor 70 transmits asignal to processor 24 indicating the passage of fastener 20. Inresponse, processor 24 activates the power supply for propellingfastener 20 through transfer system 16 to injector 18. One type ofsensor 70 that may be used with fastener delivery system 10 ismanufactured by Turck Incorporated under part numberBI2U-M12-AN4X-H1141; however, other suitable sensors or indicatingdevices may be used. Thus, fastener delivery system 10 provides for anautomatic and efficient method of transporting fasteners 20 byactivating the power supply when fastener 20 enters fastener drop 62.

Sensor 70 may also be used to notify the user of fastener deliverysystem 10 that fastener 20 did not enter fastener drop 62. For example,a predetermined time period may be entered or stored in processor 24associated with regulator 44 and sensor 70. After regulator 44 releasesa single fastener 20 from passage 38, sensor 70 may transmit a signal toprocessor 24 indicating that fastener 20 did not enter fastener drop 62within the predetermined time period. Thus, fastener delivery system 10provides greater reliability than prior art fastener delivery systems byverifying that fastener 20 has been delivered to transfer system 16.

As previously described with reference to FIG. 1, a variety of sizes andtypes of fasteners 20 may be used with fastener delivery system 10.Accordingly, referring to FIG. 2, escapement 14 may be constructed toaccommodate a variety of types and sizes of fasteners 20. For example,spacer 36 disposed between side plates 32 and 34 may be increased ordeceased in thickness to increase or decrease, respectively, the widthof passage 38 as measured from side plate 32 to side plate 34.Accordingly, each escapement 14 constructed to accommodate a particularsize or type of fastener 20 is disposed adjacent a corresponding feederbowl 12 containing the particular type or size of fastener 20. Thus,escapements 14 provide greater flexibility than prior art fastenerdelivery systems by accommodating a variety of sizes and types offasteners 20.

FIG. 3 is a schematic drawing illustrating a plan view of escapement 14shown in FIG. 2 with portions broken away. As illustrated in FIG. 3,ends of release blade 48 and stop blade 50 are disposed within passage38 for regulating the delivery of fasteners 20 to fastener drop 62.Shanks 42 of fasteners 20 are illustrated within passage 38 of FIG. 3for clarification of the operation of regulator 44.

In operation, release blade 48 and stop blade 50 retain fasteners 20within passage 38 of escapement 14 until the user of fastener deliverysystem 10 initiates an installation sequence. Upon initiation of theinstallation sequence, power supply 46 retracts release blade 48 therebyreleasing a single fastener 20 from passage 38. As best illustrated inFIG. 1, since escapements 14 are disposed at a downward angle adjacentfeeder bowls 12, gravitational forces cause the single fastener 20 toexit passage 38 and enter fastener drop 62. Referring to FIG. 3, whilerelease blade 48 is retracted, stop blade 50 is maintained in anextended position thereby preventing additional fasteners 20 fromexiting passage 38 and entering fastener drop 62.

After the single fastener 20 has been released to fastener drop 62,power supply 46 extends release blade 48 into passage 38 and retractsstop blade 50, thereby allowing another fastener 20 to travel downwardlywithin passage 38 toward release blade 48. Once another fastener 20 hasbeen located adjacent release blade 48, power supply 46 extends stopblade 50 into passage 38 to prevent additional fasteners 20 from exitingpassage 38 upon initiation of the next installation sequence.

Stop blade 50 of regulator 44 is disposed a predetermined distance fromrelease blade 48 within passage 38 to accommodate a particular type orsize of fastener 20. For example, the predetermined distance is selectedso that the predetermined distance accommodates only a single fastener20 between release blade 48 and stop blade 50. Accordingly, locatingstop blade 50 the predetermined distance from release blade 48 providesthat only a single fastener 20 will exit passage 38 and enter fastenerdrop 62 upon the retraction of release blade 48.

As illustrated in FIG. 3, fastener drop 62 includes an opening 72 fordelivery of fasteners 20 to transfer system 16. As best shown in FIG. 2,opening 72 is connected to tube 26 through tube bracket 64. Referring toFIG. 3, opening 72 is constructed generally offset from a center line ofpassage 38 so that shanks 42 enter transfer system 16 first. Forexample, opening 72 is constructed large enough to accommodate heads 40of fasteners 20. However, gravitational forces may. cause fasteners 20to flip or turn downward as fasteners 20 enter opening 72, therebycausing heads 40 of fasteners 20 to enter transfer system 16 first. Aswill be described in greater detail in conjunction with FIG. 6, havingheads 40 of fasteners 20 enter transfer system 16 first causes fasteners20 to be delivered to injector 18 in an orientation that may beunacceptable for a particular type of automatic fastener installationdevice 22.

However, since opening 72 is constructed generally offset from thecenter line of passage 38, centrifugal forces act upon fasteners 20 asfasteners 20 reach opening 72 and prevent heads 40 of fasteners 20 fromentering transfer system 16 first. For example, fasteners 20 aresupported within passage 38 by heads 40 of fasteners 20. As fasteners 20enter fastener drop 62, centrifugal forces acting upon fasteners 20cause fasteners 20 to travel around the circumference of opening 72while a portion of head 40 of fastener 20 remains supported by an uppersurface of fastener drop 62. While a portion of head 40 remainssupported by the upper surface of fastener drop 62, shank 42 of fastener20 becomes positioned within opening 72, thereby preventing head 40 offastener 20 from entering opening 72 first. Therefore, the desiredorientation of fastener 20 to accommodate automatic fastenerinstallation device 22 is maintained by ensuring that shank 42 offastener 20 enters transfer system 16 first. Therefore, upon activationof the power supply to propel fastener 20 through transfer system 16 toinjector 18, fastener 20 is transported to injector 18 in the desiredorientation.

FIG. 4 is an enlarged isometric view with portions broken awayillustrating distributor 28 of transfer system 16 shown in FIG. 1.Distributor 28 includes a housing 74 and a cover 76. Distributor 28 alsoincludes a manifold 78 and a transfer plate 80. Manifold 78 is disposedwithin housing 74 and includes openings 82 for coupling to tubes 26.Each opening 82 is constructed to accommodate a particular size tube 26depending on the type or size of fastener 20 transported within tube 26.As best illustrated in FIG. 1, the opposite ends of tubes 26 are coupledto escapements 14.

Referring to FIG. 4, transfer plate 80 of distributor 28 is disposedbeneath manifold 78 for movement along the length of manifold 78. In oneembodiment of the invention, a power supply (not explicitly shown) isprovided for translating transfer plate 80 along the length of manifold78 using a track 84; however, other suitable materials or methods may beused to provide movement of transfer plate 80 with respect to manifold78. Cover 76 of distributor 28 prevents foreign objects from enteringhousing 74 and interfering with the movement of transfer plate 80. Thetransfer of fasteners 20 from tubes 26 to tubes 30 of transfer system 16will be further described in conjunction with FIG. 5.

FIG. 5 is an exploded isometric view of portions of distributor 28 shownin FIG. 4 illustrating the cooperation of manifold 78 and transfer plate80. Tubes 30 of transfer system 16 are coupled to transfer plate 80 atopenings 86. In operation, transfer plate 80 translates along the lengthof manifold 78 and aligns a single tube 30 with a single tube 26 so thatfasteners 20 may be transported to injector 18. For example, each feederbowl 12 may contain a different size or type of fastener 20 to betransported to automatic fastener installation device 22. Accordingly,tubes 26 are constructed to accommodate the different sizes or types offasteners 20 while maintaining the desired orientation of fastener 20,thereby preventing fasteners 20 from tumbling freely within tubes 26.Tubes 30 are also constructed so that each tube 30 can accommodatefasteners 20 from one or more tubes 26 while maintaining the desiredorientation of fasteners 20, thereby preventing fasteners 20 fromtumbling freely within tubes 30. For example, as best illustrated inFIG. 1, fourteen tubes 26 are shown coupled to manifold 78 ofdistributor 28, and four tubes 30 are shown exiting distributor 28.Thus, each tube 30 is constructed to accommodate a particular size,type, range of sizes, or range of types of fasteners 20 received fromtubes 26.

In operation, transfer plate 80 translates along the length of manifold78 to align a particular tube 30 with a corresponding tube 26 so thatthe desired orientation of fastener 20 is maintained throughout transfersystem 16. For example, a user of fastener delivery system 10 selects aparticular type or size of fastener 20 to perform an installationrequirement using processor 24. Depending on the type or size offastener 20 selected, processor 24 transmits a signal to distributor 28to align tube 26 corresponding to the type or size of fastener 20selected with a corresponding tube 30. Therefore, fastener deliverysystem 10 provides greater flexibility than prior fastener deliverysystems by accommodating a variety of types and sizes of fasteners 20.

FIG. 6 is an enlarged isometric view with portions broken away ofinjector 18 shown in FIG. 1. Injector 18 includes feeder tubes 86 forreceiving fasteners 20 from tubes 30 of transfer system 16. Feeder tubes86 of injector 18 are constructed to maintain the desired orientation offasteners 20 as fasteners 20 travel through feeder tubes 86. Forexample, as illustrated in FIG. 6, each feeder tube 86 may beconstructed to accommodate a different size, type, range of sizes, orrange of types of fastener 20 while maintaining the desired orientationof fastener 20, thereby preventing fasteners 20 from tumbling freelywithin feeder tubes 86.

Injector 18 also includes a receiver 88 for receiving fasteners 20 fromfeeder tubes 86. Receiver 88 includes a plurality of receiver fingers 90for supporting and maintaining fastener 20 in the desired orientation.For example, as illustrated in FIG. 6, head 40 of fastener 20 rests onupper surfaces of two adjacent receiver fingers 90 while shank 42 offastener 20 is disposed between adjacent receiver fingers 90.

In operation, fasteners 20 are propelled through transfer system 16,into feeder tubes 86, and downward through feeder tubes 86 to receiver88. Feeder tubes 86 include slots 92 for aligning shank 42 of fastener20 between adjacent receiver fingers 90 as fastener 20 travels downwardthrough feeder tubes 86 toward receiver 88. For example, centrifugalforces cause shank 42 of fastener 20 to follow slot 92 of feeder tube 86as fastener 20 travels downwardly through feeder tubes 86 towardreceiver 88. Accordingly, when fastener 20 reaches receiver 88, shank 42of fastener 20 is aligned between adjacent receiver fingers 90.

Injector 18 also includes power supplies 94, 96, 98, and 100. Powersupplies 94, 96, 98 and 100 may comprise pneumatic power supplies or mayinclude other suitable types of power supplies. Power supply 94 iscoupled to receiver 88 to provide translating movement of receiver 88 inthe direction indicated by arrows 102 so that fasteners 20 disposedbetween receiver fingers 90 are aligned with a receiving mechanism (notexplicitly shown) of automatic fastener installation device 22. Forexample, the receiving mechanism of automatic fastener installationdevice 22 is generally located in a fixed position with respect toinjector 18. However, depending upon a specific installationrequirement, injector 18 may receive fasteners 20 from any one of feedertubes 86. Accordingly, fasteners 20 are aligned with the receivingmechanism of automatic fastener installation device 22 by translatingreceiver 88 into alignment with the receiving mechanism of automaticfastener installation device 22.

Power supply 96 is coupled to feeder tubes 86 to provide translatingmovement of feeder tubes 86 in the direction indicated by arrows 102 sothat fasteners 20 exiting feeder tubes 86 toward receiver 88 are alignedbetween corresponding receiver fingers 90. For example, as describedabove, receiver 88 is translated in the direction indicated by arrows102 to align fasteners 20 with the receiving mechanism of automaticfastener installation device 22. Accordingly, feeder tubes 86 aretranslated in the direction indicated by arrows 102 to correspond to thelocation of receiver 88. For example, feeder tubes 86 and the distancebetween adjacent receiver fingers 90 are constructed to accommodate avariety of types and sizes of fasteners 20 while maintaining the desiredorientation of fasteners 20. Accordingly, each feeder tube 86 will havea corresponding pair of receiver fingers 90 for receiving fasteners 20for maintaining the desired orientation of fasteners 20. Thus, powersupply 96 translates feeder tubes 86 to align a particular feeder tube86 with a corresponding pair of receiver fingers 90.

Power supply 98 is coupled to receiver 88 to provide translatingmovement of receiver 88 in the direction indicated by arrows 104. Asillustrated in FIG. 6, receiver 88 is shown having receiver fingers 90disposed beneath feeder tubes 86. Power supply 98 functions to retractreceiver 88 from beneath feeder tubes 86 so that the exit of each feedertube 86 is clear of receiver fingers 90. For example, a user may purgefastener delivery system 10 of foreign debris, incorrectly specifiedfasteners 20, or the like, by retracting receiver 88 using power supply98 and activating the power supply used to propel fasteners 20 throughtransfer system 16. Once the purging operation is complete, power supply98 extends receiver 88 to a position beneath feeder tubes 86 inpreparation for the next installation sequence. Thus, fastener deliverysystem 10 provides for an efficient method of purging fastener deliverysystem 10.

FIG. 7 is an enlarged isometric view of receiver 88 shown in FIG. 6. Asbest illustrated in FIG. 7, the distance between adjacent receiverfingers 90 may be varied to accommodate a variety of sizes and types offasteners 20. Injector 18 also includes injector blades 106 disposedbetween adjacent receiver fingers 90 for delivering fasteners 20 fromreceiver 88 to the receiving mechanism of automatic fastenerinstallation device 22. For clarity, only a single injector blade 106 isshown in FIG. 7.

Referring to FIGS. 6 and 7, power supply 100 is coupled to injectorblades 106 for extending and retracting injector blades 106 betweenreceiver fingers 90 in the direction indicated by arrows 104. Forexample, power supply 100 extends injector blades 106 from betweenreceiver fingers 90 to deliver fastener 20 from receiver 88 to thereceiving mechanism of automatic fastener installation device 22. Oncefastener 20 has been delivered to automatic fastener installation device22, power supply 100 retracts injector blades 106 in preparation forreceiving another fastener 20. Therefore, the desired orientation offastener 20 is maintained from receiver 88 to automatic fastenerinstallation device 22.

Referring to FIG. 7, injector 18 may be constructed so that a singleinjector blade 106 may be extended and retracted, or injector 18 may beconstructed so that all injector blades 106 extend and retract together.For example, injector 18 may be constructed so that any fasteners 20disposed between any receiver fingers 90 are purged from receiver 88 byextending all injector blades simultaneously. Thus, injector 18 providesa method of purging fasteners 20 from between receiver fingers 90 ofreceiver 88.

Referring to FIG. 1, the operation of fastener delivery system 10 willbe briefly described. To meet a specific fastener 20 installationrequirement, a user of fastener delivery system 10 selects a particulartype or size of fastener 20 using processor 24. Upon the selection ofthe particular type or size of fastener 20, distributor 28 aligns one oftubes 26 with one of tubes 30 so that the particular fastener 20 may betransported from one of feeder bowls 12 containing the particularfastener 20 to injector 18. When the user is ready to initiateinstallation of fastener 20, using the processor 24, the user activatesregulator 44, as best shown in FIG. 2, to release the particularfastener 20 from escapement 14.

After the particular fastener 20 is released from regulator 44 ofescapement 14, as the particular fastener 20 passes sensor 68, a powersupply, such as a pneumatic power supply or other suitable power supply,is activated to propel the particular fastener 20 through transfersystem 16 to injector 18. Accordingly, the particular fastener 20 entersopening 72 of fastener drop 62 and is propelled through tube 26,distributor 28, tube 30, to injector 18. Referring to FIG. 1, fastenerdelivery system 10 may also include a sensor 108 for deactivating thepower supply used for propelling fastener 20 through transfer system 16.For example, sensor 108 may be associated with tubes 30 near injector 18so that when sensor 108 detects the passage of fastener 20 through tubes30, sensor 108 transmits a signal to processor 24 indicating thatfastener 20 has been delivered to injector 18. In response to the signalreceived from sensor 108, processor 24 deactivates the power supply forpropelling fastener 20 through transfer system 16. One type of sensor108 that may be used with fastener delivery system 10 is manufactured byTurck Incorporated under part number BI40-R325R-UN6X; however, othersuitable sensors or indicating devices may be used.

Once the particular fastener 20 reaches injector 18, injector blades 106extend to deliver the particular fastener 20 from receiver 88 ofinjector 18 to the receiving mechanism of automatic fastenerinstallation device 22. Therefore, fastener delivery system 10 providesan efficient and reliable method of delivering fasteners 20 in a desiredorientation to automatic fastener installation device 22, therebydecreasing the time required to install fasteners 20. The operation offastener delivery system 10 may be controlled by a user or operated in acompletely automatic way without the need for user intervention. Somecombination of user controlled and automatic operation is within theskill of the art.

FIG. 8 illustrates a flow chart of a method for delivering fasteners 20in a desired orientation to automatic fastener installation device 22according to the present invention. Fasteners 20 are placed in feederbowls 12 at step 200. Each feeder bowl 12 may contain a different typeor size of fastener 20 to accommodate various installation requirements.

Fastener delivery system 10 determines whether fasteners 20 are presentwithin escapements 14 at step 210. Sensor 68 coupled to escapements 14detects whether additional fasteners 20 are required within passage 38of escapements 14 at step 220. If additional fasteners 20 are required,the method proceeds to step 230. If no additional fasteners 20 arerequired, the method proceeds to step 260.

Sensor 68 transmits a signal to processor 24 indicating that additionalfasteners 20 are required within escapements 14 at step 230. Inresponse, processor 24 activates feeder bowls 12 to initiate delivery offasteners 20 from feeder bowls 12 to escapements 14. Sensor 68 continuesto detect whether additional fasteners 20 are required within passage 38of escapements 14 at step 240. If additional fasteners 20 are requiredwithin passage 38 of escapements 14, the method proceeds to step 230. Ifno additional fasteners 20 are required within passage 38 of escapements14, the method proceeds to step 250.

Sensor 68 transmits a signal to processor 24 indicating that noadditional fasteners 20 are required within escapements 14 at step 250.In response, processor 24 deactivates feeder bowls 12 to cease thedelivery of additional fasteners 20 from feeder bowls 12 to escapements14.

A user of fastener delivery system 10 selects a particular type or sizeof fastener 20 at step 260 as required to meet a particular installationrequirement. For example, processor 24 may include a displayrepresenting the types and sizes of fasteners 20 available in eachfeeder bowl 12. By selecting a particular type or size of fastener 20 orfeeder bowl 12, the user may initiate the installation sequence to meetthe required installation requirement using automatic fastenerinstallation device 22. Alternatively, the type and size of fastener 20may be pre-programmed with processor 24 as is well known to thoseskilled in the art.

Based on the fastener 20 or feeder bowl 12 selected at step 260,fastener delivery system 10 aligns transfer system 16 at step 270. Forexample, distributor 28 aligns one of tubes 26 coupled to the selectedescapement 14 and feeder bowl 12 with one of tubes 30 so that thedesired orientation of fastener 20 is maintained throughout transfersystem 16. For example, since each tube 30 is constructed to accommodatea variety of types or sizes of fasteners 20 while maintaining a desiredorientation of fastener 20, fastener delivery system 10 aligns acorresponding tube 30 based on the type or size of fastener 20 selectedat step 260.

Based on the fastener 20 or feeder bowl 12 selected at step 260,fastener delivery system 10 also aligns injector 18 at step 280. Forexample, since feeder tubes 86 and the distance between receiver fingers90 of injector 18 are constructed to accommodate a variety of sizes ortypes of fasteners 20 while maintaining a desired orientation offastener 20, fastener delivery system 10 aligns receiver fingers 90 andone of feeder tubes 86 corresponding to the type or size fastener 20selected at step 260 with the receiving mechanism of automatic fastenerinstallation device 22. As best shown in FIG. 6, fastener deliverysystem 10 aligns receiver fingers 90 and feeder tubes 86 in thedirection indicated by arrows 102.

Referring to FIG. 8, fastener delivery system 10 initiates delivery offastener 20 to automatic fastener installation device 22 at step 290.For example, power supply 46 of regulator 44 retracts release blade 48thereby releasing a single fastener 20 from passage 38 of escapement 14.

Fastener delivery system 10 detects the passage of the single fastener20 from passage 38 of escapement 14 to fastener drop 62 at step 300.Sensor 70 of fastener delivery system 10 detects the passage of thesingle fastener 20 entering fastener drop 62 at step 310. If sensor 70detects the passage of the single fastener 20, sensor 70 transmits asignal to processor 24 indicating the passage of the single fastener 20and the method proceeds to step 320. If sensor 70 does not detect thepassage of the single fastener 20 entering fastener drop 62, sensor 70transmits a signal to processor 24 indicating that the single fastener20 did not enter fastener drop 62, thereby notifying the user offastener delivery system 10 that the installation sequence cannotproceed.

In response to receiving the signal from sensor 70 that a singlefastener 20 has entered fastener drop 62, processor 24 transmits asignal activating the power supply for propelling the single fastener 20through transfer system 16 at step 320. Fastener delivery system 10detects the passage of the single fastener 20 through transfer system 16using sensor 108 at step 330. If sensor 108 detects the passage of thesingle fastener 20 through transfer system 16, sensor 108 transmits asignal to processor 24 indicating the passage of the single fastener 20at step 340 and the method proceeds to step 350. If sensor 108 does notdetect the passage of the single fastener 20 through transfer system 16,sensor 108 transmits a signal to processor 24 indicating that the singlefastener 20 was not transferred through transfer system 16, therebynotifying the user of fastener delivery system 10 that the installationsequence cannot proceed.

In response to receiving the signal from sensor 108 that the singlefastener 20 has been transferred through transfer system 16, processor24 transmits a signal to deactivate the power supply used to propel thesingle fastener 20 through transfer system 16 at step 350. At thispoint, the single fastener 20 is disposed between adjacent receiverfingers 90 of injector 18. Fastener delivery system 10 activatesinjector 18 to deliver the single fastener 20 from injector 18 to thereceiving mechanism of automatic fastener installation device 22 at step360. Fastener delivery system 10 extends injector blades 106 of injector18 thereby delivering the single fastener 20 to automatic fastenerinstallation device 22. Fastener delivery system 10 then retractsinjector blades 106 after delivering the single fastener 20 to automaticfastener installation device 22 in preparation for the next installationsequence.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions, andalterations, can be made therein without departing from the spirit andscope of the present invention as defined by the appended claims.

What is claimed is:
 1. A fastener injector comprising: a receiver havinga first receiver slot and a second receiver slot, each of the first andsecond receiver slots formed by spaced apart receiver fingers, thespacing between the receiver fingers forming the first receiver slotdifferent than the spacing between the receiver fingers forming thesecond receiver slot for receiving different sizes and types offasteners in a desired orientation in each of the first and secondreceiver slots; and a plurality of injector blades operable to extendinto the first and second receiver slots to deliver the fasteners in thedesired orientation from the receiver to a fastener installation device.2. The injector of claim 1, further comprising a plurality of feedertubes operable to deliver the fasteners in the desired orientation tothe receiver.
 3. The injector of claim 2, further comprising a powersupply operable to align one of the feeder tubes with one of the firstand second receiver slots.
 4. The injector of claim 1, furthercomprising a plurality of feeder tubes operable to deliver the fastenersin the desired orientation to the receiver, wherein each feeder tubeincludes a slot operable to align the fasteners with the first andsecond receiver slots.
 5. The injector of claim 1, further comprising apower supply operable to extend the plurality of injector blades todeliver the fasteners to the fastener installation device.
 6. Theinjector of claim 1, further comprising: a plurality of feeder tubeseach having an exit disposed adjacent the receiver; and a power supplyoperable to move the receiver from adjacent the exit of the feeder tubessuch that the exit of the feeder tubes is clear of the receiver.
 7. Theinjector of claim 1, further comprising a power supply operable to alignone of the first and second receiver slots with the fastenerinstallation device.
 8. The injector of claim 1, further comprising: aplurality of feeder tubes operable to deliver the fasteners to thereceiver; a first power supply operable to move the tubes to align oneof the tubes with one of the first and second receiver slots; and asecond power supply operable to move the receiver to align one of thefirst and second receiver slots with the fastener installation device.9. A method for delivering a plurality of different sizes and types offasteners to a fastener installation device, the method comprising:delivering the fasteners in a desired orientation to a receiver using aplurality of tubes, the receiver having first and second receiver slots,each of the first and second receiver slots formed by spaced apartreceiver fingers, the spacing of the receiver fingers forming the firstreceiver slot different than the spacing of the receiver fingers formingthe second receiver slot for receiving different sizes and types offasteners in each of the first and second receiver slots; andtransferring the fasteners in the desired orientation from the receiverto the fastener installation device using a plurality of injectorblades.
 10. The method of claim 9, further comprising aligning one ofthe tubes with one of the first and second receiver slots.
 11. Themethod of claim 9, wherein the transferring step comprises extending theplurality of injector blades into the first and second receiver slots totransfer the fasteners from the receiver to the fastener installationdevice.
 12. The method of claim 9, further comprising aligning one ofthe first and second receiver slots with the fastener installationdevice.
 13. The method of claim 9, further comprising moving thereceiver from a first position adjacent an exit of the tubes to a secondposition clear of the exit of the tubes for purging the fasteners fromthe tubes.
 14. The method of claim 9, further comprising aligning thefasteners with one of the first and second receiver slots using a slotformed in the tubes, the slot adapted to receive a shank of thefasteners.
 15. A fastener injector comprising: a plurality of tubes,each tube sized to transfer different sizes and types of fasteners in adesired orientation; a receiver having first and second receiver slots,each of the first and second receiver slots formed by spaced apartreceiver fingers, the spacing between the receiver fingers forming thefirst receiver slot different than the spacing between the receiverfingers forming the second receiver slot, the spacings between thereceiver fingers sized to receive and retain different sizes and typesof fasteners from the tubes in each of the first and second receiverslots; and a plurality of injector blades operable to transfer thefasteners in the desired orientation from the receiver to a fastenerinstallation device.
 16. The injector of claim 15, wherein at least oneof the tubes includes a slot operable to align the fasteners with one ofthe first and second receiver slots.
 17. The injector of claim 15,wherein the plurality of injector blades is operable to extend into thefirst and second receiver slots to deliver the fasteners to the fastenerinstallation device.
 18. The injector of claim 15, wherein at least oneof the tubes is further operable to transfer a range of sizes and typesof fasteners in the desired orientation.
 19. The injector of claim 15,further comprising: a first power supply operable to move the tubes toalign one of the tubes with one of the first and second receiver slots;and a second power supply operable to move the receiver to align one ofthe first and second receiver slots with the fastener installationdevice.
 20. The injector of claim 19, further comprising a third powersupply operable to move the receiver from a first position adjacent anexit of the tubes to a second position clear of the exit of the tubes.